Sustain Ability Sustain.Ability. Steve Padasak – Finch ... · Steve Padasak – Finch Paper, Benoit Comtois, Rick Van Fleet-Honeywell 1 esso s ea ed by c ape s o e House Bailey

Sustain Ability2012 Honeywell Users Group Americas

Sustain.Ability.

Lessons Learned by Finch Paper’s Power

Steve Padasak – Finch Paper, Benoit Comtois, Rick Van Fleet-Honeywell

1

esso s ea ed by c ape s o eHouse Bailey HMI Migration

FINCH PAPER, GLENS FALLS, NYFINCH PAPER, GLENS FALLS, NY

2

BackgroundBackground

• Finch Paper LLC is located in Glens Falls, NY• Originally built in 1865 as a sawmill, shortly converted

in to a paper mill.• 700 tpd of sulphite pulp700 tpd of sulphite pulp.• Continuous digester, 4 Paper machines• Variety of end products including uncoated text &

d di it lcover, and digital papers.• DCS Migration to Experion started March 2010• Chlorine Dioxide Generator and Bleach Plant I/OChlorine Dioxide Generator and Bleach Plant I/O

converted to Experion R300 controllers• APC completed on both areas using Profit Controller

and BTG specialty sensors

3

and BTG specialty sensors

DCS Modernization ObjectivesDCS Modernization Objectives

• SafetyP l d A t P t ti– Personnel and Asset Protection

– Reduce Risk of Incident Due to Obsolescence– Ensure Regulatory Compliance $$$$

• Business Continuity– Maximize System Reliability – Reduce Unplanned DowntimeReduce Unplanned Downtime

• Business Performance– Reduced Total Cost of Ownership– Support Go-To-Market Strategy with more production agility,

quality improvements and reducing fixed costs

• Enterprise Business Integration

4

p g– Integrating system architecture (I/O; DCS; MES; ERP)

Finch Paper - Current Process Control Systems850# Steam

Boiler # 4Gas/Oil100 K

Bailey DCSBailey + CyTech

Boiler # 5Gas/Oil100 K


Boiler # 9Bark/Gas/Oil

140 KBailey DCS

Bailey + CyTech

Boiler # 8Liquor125 K


Boiler # 10Liquor145K


Boiler # 1 Boiler # 2 Boiler # 3 Boiler # 6 Boiler # 7

21.5 MWTurbine Generator850# / 200# / 50#

GE Mark V Controls50 # Steam

Power HouseControl Room

Oil60 K

Bailey DCSBailey & CyTech

Gas/Oil100 K


Gas/Oil100 K


Liquor65 K


Liquor65 K


GE Mark V Controls

200 # SteamLiq

uor

Liq

uor

EvaporatorsPulp MillBleach PlantPaper Machines

Evaporator# 1


Evaporator# 2


EvaporatorControl Room

Woodyard

PLC &Manual Controls

WoodyardControl Room

COMPLETE 2012

SulphurBurner

Panel Board Controls

DigesterPanel Board

&MxOpen

Brown StockWashers

Panel Board

ScreeningPanel Board

& PLC

Pulp MillControlRoom COMPLETE 2011

Bleach PlantExperion& PLC &

Bleach PlantControl RoomPaper Machine #1

MxOpen DCS & QCSLocal Machine Controls Paper Machine #2


M O DCS & QCS

ConvertingAB PLC

Local Controls R8 / CLO2Experion

& PLC

Stock BlendingMxOPEN

Chemical PrepPCC

5 HONEYWELL - CONFIDENTIAL File Number

& PLC &Panel Board


MxOpen DCS & QCSLocal Machine Controls

ConvertingMultiple

Locations

& PLC

Stock PrepControl Room

ProvoxChemical Prep

Migration Options


Rip and Replace Can be Very Costly

Why Finch Choose to Migrate

• Bailey MCS Consoles obsolete, difficult getting t ( B )parts (eBay)

• Unplanned shutdowns ($$$$)• Poor documentation affecting troubleshooting• Poor documentation affecting troubleshooting

resulting in extended downtime• No remaining Bailey expertise on site and in area


Mi i i O ti l I t Th j t ill b

Project Goals

• Minimize Operational Impact – The project will be installing migrated displays based on the existing Bailey graphics. The new displays will initially be run i ll l ith th t di l Th KPI ill bin parallel with the current displays. The KPI will be considered successful if the commissioning effort is complete in one week and if Finch Operations is able t t iti i ti t th tto transition primary operations to the new system without going back to the Bailey system.

•Retain Productivity – Finch Operations should be able to operate the plant at the same levels of productivity as prior to the cutover. This will beproductivity as prior to the cutover. This will be accomplished by effective use of the Operator Training and by a thorough Acceptance Test.


Bailey Interface / Architecture Bailey Interface / Architecture Options ReviewOptions Review

ARCHITECTURE BASISARCHITECTURE BASISARCHITECTURE BASISARCHITECTURE BASIS

EPKS Data Server BPCS

• Honeywell Experion PKS systems uses OPC to interface bi-directionally with exposedto interface bi directionally with exposed Infi90 exception rate function code data for HMI operations.

• Data is retrieved by “Rovisys OPC90” via a

Rovisys OPC90Server

Data is retrieved by Rovisys OPC90 via a communication interface unit “CIU”.

CIUCIU

Infi90 Loop

Server Redundancy FailoverServer Redundancy Failover

Failure ScenarioS S

Server Redundancy FailoverServer Redundancy Failover

OPC ServerFailureExperion FailureStation1 Station2

Running

StandBy

Failed

ExpREDServerA ExpREDServerB

Transparent to OperationOPC Reconnect delay

See Next slide

RDM RDM

OPCA OPCB

RDM Manage Failover

CIU CIU

Experion failover

SCADA Point StructureSCADA Point StructureSCADA Point StructureSCADA Point Structure

OPC Client access can be directly linked to an OPC source item.

Native parameter exposed by Experion OPC Server Data Access.Can be Accessed Read Only or Read and Write by an OPC client.

User defined parameter exposed by Experion OPC Server Data Access.

Can be accessed Read Only or Read and Writeb OPC li tby an OPC client.

OPC Process Used To Populate DatabaseOPC Process Used To Populate DatabaseOPC Process Used To Populate Database OPC Process Used To Populate Database

Upon Experion Server failover:

OPC Data Access ClientOPC Data Access Client-Starts-Create connection to OPC Server-Adds Items 1 by one and Itemsbecomes available 1 by one

OPC Integrator -Starts-Create connection to OPC ServerAdds Items 1 by one and Items

v

-Adds Items 1 by one and Itemsbecomes available 1 by one

The rate at which this happens isdependant of few things like:

v

p gComputer performancesRAM memory availableNetwork performance

Experience says in the order of:v

Experience says in the order of:1000 items per seconds. This means only test will validate

Experion PKS / Bailey Points Building Utilityp y g y

Experion PKS / Bailey Points Building Utilityp y g y

Project Schedule

Project Phase Milestone DateKick-off Meeting and Bailey System Review 18-Jan-11 System Specification R0 Submitted to Finch 18-Jan-11 Bailey CIU Shipment to site 28-Jan-11Bailey CIU Shipment to site 28-Jan-11 System Specification R1 Submitted to Finch 31-Jan-11 Hardware Shipment to Atlanta 28-Mar-11 Hardware Shipment to site 18-Jun-11 Customer Acceptance Test 02-May-11 Operator Training 16-May-11

System commissioning and startup 23-Aug-11


Honeywell.com

HMI Migration stepsHMI Migration stepsConnection of OPC Server to

Bailey CIUBailey CIU

Existing Bailey

Infinet loop systemInfinet loop system

Honeywell Proprietary

Honeywell.com

HMI Migration step 2 – Establish Experion C i tiCommunications

Step2

• Connect and configure the Experion PKS Server and Client.

• Build the Experion PKS Server database and OPC Integrator database using the Honeywell Bailey bulk build utilitythe Honeywell Bailey bulk build utility.


Honeywell.com

HMI Migration stepsConnection of Experion EPKS

Server / Client to the OPC Server

HMI Migration steps

Server / Client to the OPC Server

Remove Bailey HMI at your convenience


Honeywell.com

Powerhouse Bailey HMI Migration –R d d t S FTERedundant Servers on FTE

Switch A

Router/Firewall to Finch B i N t kS it h B

Existing L3.5 DMZ

Existing eServer

on F

TE

Fault Tolerant Ethernet (FTE)Business Network

Redundant Experion & Rovisys OPC Servers w/ KVM Switch in Server/Switch Cabinet

Switch B

Existing PHD

Existing eServer

Experion Server A

ntro

l LA

N

CIU AExisting Customer Installed Base Bailey DCSCIU A

Experion Server B

pe o Se e

OPC Server A

Honeywell Engineering ro

cess

Co OPC Server B

CIU B

Honeywell Operator Stations (Desktops Mounted in Server Cabinet)g g

Station (Desktop)

oney

wel

l P


Ho

Remote Video/Keyboard/Mouse via Honeywell Remote Peripheral Evaporator Control Room

Nema 4X Enclosurefor 6 & 7 Boilers

Honeywell.com

Interface Cabinets


Honeywell.com

Experion Consoles


Honeywell.com

Schematic Conversions


Lessons Learned

• Careful review of existing database is required.• Be careful about simply cloning database if it isBe careful about simply cloning database if it is

not properly documented.• Upfront systems assessment (FEED) can save

money in the long runmoney in the long run.• Involve operators in review of graphic design to

learn their hot buttons.• Allow for sufficient time to fully check system out

before cutover.


Results and Next Steps

• Operator acceptance increasing with use and t i itraining

• Experion trending is a big improvement over Bailey.a ey

• Project execution went well.


Questions?


Documents

Sustain Ability Sustain.Ability. Steve Padasak – Finch ... · Steve Padasak – Finch Paper, Benoit Comtois, Rick Van Fleet-Honeywell 1 esso s ea ed by c ape s o e House Bailey